Independent Test Laboratory Kiwa-Pelveld today published the 11th edition of the PV module Reliability Corecard, with extensively tested PV modules from 50 different manufacturers. The score card reveals improvements in energy yield per watt-peak and resistance to the potential induced demolition, but an increase in fracture under mechanical stress and hail simulations, and a generally higher failure percentage is a reason to concern for many.
The Reliability Corecard module, published annually by PV Module Testing Laboratory Kiwa-Pvel, has released its 11one edition today. The Scorecard summarizes the results of extensive reliability tests from on the market available PV modules, designed to expose any weaknesses that can appear in the field after installation.
The Scorecard 2025 contains results of 50 module manufacturers, a slight decrease of 53 included in last year’s score card. Tristan Erion-Lorico, vice-president of sales and marketing at Kiwa-Pvel, noted that 15 manufacturers did not return in 2024 to participate in this year’s test round, while various newcomers also register.
The good news
Of the 50 manufacturers and many products that are included in the tests, 21 reached the status ‘top performance’ in all categories. In general, the resistance was against Potential-induced demolition improvements in most manufacturers and pan-performance-where tested module characteristics are used to simulate the performance of the energy yield-also also improved, with the latest harvest of modules that generate more energy compared to their energy class. Erion-Lorico attributed this to improved bifaciality and better temperature coefficients for the latest cell and module technologies.
Resistance to Ultraviolet -induced demolition, which has emerged as a special care for the tunneloxide -passivated contact (Topcon) cells that now represent most of the market, also turned out to improve, but still represents an area where manufacturers have to take precautions.
Quality problems
Modules that have been tested for this year’s score card revealed at least performance loss after hail and other mechanical stress testing – possibly a sign of improving cell cracks that has long been a great risk for the performance of PV module in the field.
But this phase of the test also showed one of the biggest care for the PV industry in 2025, with a pronounced increase in the fracture of the module. Cracked module glass, broken frames and other problems such as damage to the connection box all saw an increase. Erion-Lorico noted that 20% of the tested models experienced at least one failure during mechanical tax tests, an increase of only 7% in both the Scorecards 2023 and 2024, and that the cargo tests performed as part of the reliability scorecard up to 1800 Specelstand. “These are the types of conditions that can occur in the field with wind loads and snow loads. And I do not know which other industry would accept a failure percentage of 20%.”
Image: Kiwa-Pel
These raised fracture rates have already been seen in the field in recent years and the switch to larger module formats, made with thinner glass, is part of the problem. But it also comes down to cost savings, since manufacturers try to reduce material consumption in times of low prices for PV components. “The biggest about aspect of this report is probably that the fracture of the module has really increased, which has a direct correlation with cost savings,” said Erion-Lorico.
In some cases, the lack of incoming material on the edge of a module turned out to be sufficient to cause glass fracture, with soldering points on the glass that create voltage concentration points. This allows even daily temperature changes to be sufficient to break glass on the edges. “There is a series of causes, whether the problems with glass reinforcement, defects in the glass, weaker frame designs, squeezing the laminates, poor frame sealing employees and more aggressive mounting systems,” Erion-Lorico added.
Image: Kiwa-Pel
De tests vertoonden ook een toename van het totale faalpercentage, waarbij producten van 83% van de fabrikanten ten minste één testfout registreren en stijgen van 66% in de scorecard 2024. Breuk tijdens mechanische stress of hagel testen vertegenwoordigde de grootste toename, maar Erion-Lorico zei ook dat modules die faalden, noch stroomverlies of visuele inspectie na thermische fietsen, ook toegenomen, evenals Connection box-related problems, and for the first time ‘witness’ failures, in which a manufacturer decided to send modules that did not have a PVV selection process, were seen in 2025.
In general, improvements in the simulated energy output show the value of the innovation of the PV industry and the rapid introduction of new technologies into production for many products. But because the manufacturers of PV module continue to look for all possible cost reductions in the light of extremely low component prices, the effects on quality are shown.
“The rapid pace of innovation in the landscape of the PV module is encouraging and it is great to see more products reaching the status of top performance,” said Erion-Lorico. “However, we continue to warn that buyers do not assume that all modules have been created. Our tests remain considerable variability in performance and long -term reliability.
The full score card is available on scorecard.pvel.com
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